Sprayer actuator, sprayer, and method of making the same

ABSTRACT

A sprayer actuator, a sprayer, and a method of making the same are disclosed. In one embodiment, the sprayer includes an ergonomic sprayer actuator with a housing having an upper portion, a lower portion for fitting over a can, and a narrowed waist portion between the upper portion and the lower portion.

FIELD OF THE INVENTION

[0001] The present invention relates to a sprayer, a sprayer actuator,and a method of making the same.

BACKGROUND OF THE INVENTION

[0002] Pressurized containers of the aerosol type have beentraditionally equipped with an actuating button or cap, which button orcap defines a product duct through which the product passes to thedischarge orifice situated within the button or cap. To dischargeproduct from the container, the user grasps the container and with onefinger of the grasping hand depresses the button or a portion of the capto release the contents of the container.

[0003] While achieving substantial commercial success, finger actuatedbuttons or caps have the disadvantage of inducing finger fatigue forsome users. Moreover, with the prior systems of actuation, the aiming ofthe discharged product to the desired surface area suffers somewhat dueto the relatively awkward gripping and finger placement. A more naturalgrasping and actuation of the container is achieved through the use of atrigger mechanism. Examples of prior trigger actuated aerosol containersare disclosed in U.S. Pat. Nos. 3,189,232, 3,580,432; 3,987,942;5,862,960; and 6,494,349 B1. In addition, some prior spray containersare only held by a few of the user's fingers. These may result in a lessthan adequately secure grip, and supporting the weight of the sprayermay place an undue strain on the user's fingers. Therefore, the searchfor improved sprayers has continued.

SUMMARY OF THE INVENTION

[0004] The present invention relates to a sprayer, a sprayer actuator,and a method of making the same. There are numerous embodiments of thesprayer, sprayer actuator, and method described herein, all of which areintended to be non-limiting examples, and there are numerous aspectsthereof that may constitute inventions in their own right.

[0005] In one embodiment, an ergonomic sprayer actuator is disclosed.The sprayer actuator comprises a housing having an upper portion, alower portion for fitting on or over a can or other container, and anarrowed waist portion between said upper portion and said lowerportion.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] While the specification concludes with claims particularlypointing out and distinctly claiming the invention, it is believed thatthe present invention will be better understood from the followingdescription taken in conjunction with the accompanying drawings inwhich:

[0007]FIG. 1 is a perspective view of one non-limiting embodiment of acontainer having a sprayer actuator thereon.

[0008]FIG. 2 is a side view of the spray container shown in FIG. 1.

[0009]FIG. 3 is front view of the spray container shown in FIG. 1.

[0010]FIG. 4 is a cross-sectional view of the spray container takenalong line 4-4 of FIG. 3.

[0011]FIG. 5 is a side view of the spray container showing a user's handholding the same.

[0012]FIG. 6 is a view of the sprayer container from above showing auser's hand holding the same.

[0013]FIG. 7 is an exploded perspective view showing the assembly of thecomponents of the sprayer actuator.

[0014]FIG. 8 is a perspective view of another embodiment of a sprayerwhich has a trigger disposed outside at least a portion of the actuatorhousing.

DETAILED DESCRIPTION OF THE INVENTION

[0015] The present invention relates to a sprayer, a sprayer actuator,and a method of making the same. FIG. 1 shows one non-limitingembodiment of a sprayer 20. As shown in FIG. 1, the sprayer (or “spraycontainer”) 20 comprises a container 22 and a sprayer actuator (or“actuator”) 24. The sprayer actuator 24 comprises a housing 26, atrigger 28, and a nozzle 30. The sprayer 20 can be a pressurizedcontainer sprayer, such as an aerosol sprayer, or a non-aerosol triggersprayer, or any other suitable type of sprayer which can benefit fromthe features described herein.

[0016] The container 22 can be any suitable type of container forholding a product to be dispensed by the sprayer. In some embodiments,it is desirable for the container 22 to be capable of holding contentsthat are under pressure and/or a propellant. The design of suchcontainers in the form of metal cans is well known. The container 22 canbe of any suitable shape. The container 22 has a base 32, sides 34, alower portion 36, an upper portion 38, and a top 40 (shown in FIG. 4).In the embodiment shown, the container 22 is generally cylindrical, butthe sides 34 of the container taper inwardly with a slightly convexcurvature on the upper portion 38 of the container. The container 22 is,thus, narrower at its upper portion 38. The container 22 can havenumerous other shapes in different embodiments.

[0017] The container 22 can contain any suitable product that is capableof being sprayed by the sprayer 20. The product can be in any suitableform, including liquids, and other compositions. Examples of productsinclude, but are not limited to: air freshening compositions, fabricfreshening compositions, ironing aids such as spray starches,insecticides, paints, and other industrial, commercial, household,automotive, and/or garden compositions.

[0018] The container 22 can also include a propellant for dispensing theproduct therein. Any suitable propellant can be used. Suitablepropellants include, but are not limited to: hydrocarbon propellantssuch as: isobutene, butane, isopropane, dimethyl ether (DME), ornon-hydrocarbon propellants such as compressed gases which include, butare not limited to compressed air, nitrogen, inert gases, carbondioxide, and mixtures thereof. In certain embodiments, such as in thecase of air freshening compositions, it may be desirable for thepropellant to be substantially free of hydrocarbon propellants.

[0019] The actuator housing 26 in the embodiment shown, has a lowerportion 42, an upper portion 44, a waist portion 46, and a top 48. Thelower portion 42 fits on or over the container 22. As shown in FIG. 1,in this embodiment, the waist portion 46 is located between the lowerportion 42 and the upper portion 44. The waist portion 46 is narrowerthan the widest portions of the upper and lower portions. The waistportion 46 provides the sprayer actuator 24 with an ergonomic design.Specifically, as shown in FIG. 5, in this embodiment, actuator housing26 is configured so that a user can wrap at least their thumb 50 andforefinger 52 around the narrowed waist portion 46. In this embodiment,the sprayer actuator housing 26 is also provided with a configurationthat permits it to comfortably fit the natural contour of the user'spalm, such as in the crease in the user's palm. As shown in FIG. 6, whenviewed from above, at least a part of the upper portion 44 extendsoutward beyond the portion of the user's thumb 50 and forefinger 52 thatare in contact with the narrowed waist portion 46 to form a ledge.

[0020] The narrowness of the waist portion 46 makes the sprayer 20easier to grip. In addition, since the upper portion 44 comprises atleast portions that are wider when viewed from above than the portion ofthe user's hand that at least partially encircles the waist portion 46,the ledge formed by these portions of the upper portion 44 can rest on aportion of the user's thumb and forefinger to at least partially supportthe weight of the sprayer 20 during use. This can relieve the pressureon the user's fingers and/or wrist, particularly when the sprayer 20 isused for a prolonged period.

[0021] The upper portion 44 may comprise portions at the front, sides,and rear of the sprayer that are wider than the portions of the user'shand that are in contact with the narrowed waist portion 46. In otherembodiments, the upper portion 44 need not have portions that are widerall the way around the sprayer than the portions of the user's hand thatare in contact with the narrowed waist portion 46. Any suitableportion(s) of the upper portion 44 may extend laterally outward beyondthe portions of the user's hand that are in contact with the narrowedwaist portion 46. Such suitable portions include, but are not limited toon at least one of the sides, preferably both sides, and/or in the backof the sprayer.

[0022] In the embodiment shown in the drawings, the lower portion 42 ofthe actuator housing 26 is larger and extends downward further towardthe base 32 of the container 22 in the back of the sprayer 20 than inthe front of the sprayer. In other embodiments, the lower portion 42 ofthe actuator housing 26 may have a different configuration. For example,in other embodiments, all parts of the lower portion 42 of the actuatorhousing 26 can be of uniform length.

[0023] As shown in the drawings, in this embodiment, the upper portion44 of the actuator housing 26 has a front, a back, and an underside 49.In the embodiment shown, both the underside 49 and the top 48 of theactuator housing 26 are angled or tilted upward from the back of thesprayer to the front of the sprayer. The fact that the underside 49 ofthe upper portion 44 is tilted so that the underside of said upperportion is higher in front than in the back allows the sprayer to beheld more comfortably by a user without bending the user's wrist. Inother embodiments, the top 48 (and/or the underside 49) of the housingcan have a different configuration (e.g., flat, tilted downward, etc.).In some embodiments, it may even be possible to eliminate the top 48 ofthe housing 26 altogether.

[0024] In the embodiment shown in the drawings, the top 48 of theactuator housing 26 is tilted upward because the sprayer nozzle 30 isoriented so that liquid sprayed from the nozzle 30 will be directed atan angle of greater than 0° and less than 90°. That is, the liquid isnot sprayed out parallel to the base 32 (that is, horizontally when thebase is placed on a horizontal surface), nor is it sprayed outvertically (straight upward in the direction of the axis of thecontainer). In other embodiments, the liquid sprayed from the nozzle 30is directed at an angle of greater than or equal to about 30° and lessthan or equal to about 60°. In other embodiments, the liquid sprayedfrom the nozzle 30 is directed at an angle of about 45°. In otherembodiments, the liquid sprayed from the nozzle 30 is directed at anangle of between about 20°-25°.

[0025] In other embodiments, however, it may be desirable for the liquidsprayed from the nozzle 30 to be sprayed horizontally (0°) or vertically(90°). In still other embodiments, such as in the case of an ironingaid, it may be desirable for the liquid sprayed from the nozzle 30 to bedirected downward toward a surface (at an angle of between 0° and −90°).It is appreciated, however, that spray patterns are typically in theform of dispersions, and the spray emitted from a nozzle will form adispersed spray pattern angle when viewed from the side. The angles ofspray referred to herein are the central axis, A, as shown in FIG. 2,that bisects such a spray pattern. It is understood that portions of thespray pattern will typically be distributed on either side of thiscentral axis.

[0026] The nozzle 30 may be configured to spray droplets of any suitablesize. In one non-limiting embodiment, the nozzle 30 is configured tospray a plurality of droplets wherein at least some of the spraydroplets have a diameter in a range of from about 0.01 μm to about 500μm, or from about 5 μm to about 400 μm, or from about 10 μm to about 200μm. The mean particle size of the spray droplets may be in the range offrom about 10 μm to about 100 μm, or from about 20 μm to about 60 μm.These size droplets may be useful in the case of air fresheningcompositions in which it is desired to suspend the droplets in the airfor prolonged periods.

[0027] The sprayer actuator 24 comprises a trigger 28 operativelyassociated with the actuator housing 26 at the front of said sprayer. Inthe embodiment shown, the trigger 28 is also ergonomically designed. Thetrigger 28 is ergonomic in that it is relatively long, flat, and wide.This permits the user to not only activate the trigger with one finger,such as the user's index finger; it also allows the user to use two ormore fingers (such as their index and middle fingers) to activate thetrigger 28. This reduces fatigue on the user's index finger in the caseof prolonged spraying. The trigger 28 can have any suitable dimensions.In certain embodiments, the trigger can have a length, L, of greaterthan or equal to about 1.25 inches (about 30 or 32 mm). In certainembodiments, the trigger 28 can have a width, W, of greater than orequal to about {fraction (7/16)} inch (about 10 or 11 mm). For example,the trigger 28 may have a width of about {fraction (10/16)} inch (about15 or 16 mm). In other embodiments, the trigger 28 need not beergonomically designed, and can be of a more conventional design andsize.

[0028]FIGS. 4 and 7 show the details of the inside of the sprayeractuator 24. As shown in FIGS. 4 and 7, this embodiment of the sprayer20, the sprayer actuator 24 comprises the actuator housing 26 andtrigger 28 described above. The actuator housing 26 has a hole oropening 54 in the front for the trigger 28. The trigger 28 is part of alarger trigger piece 56, and the rear of the trigger piece 56 has a bar58 joined thereto, or integrally formed therewith. The trigger piece 56also comprises a bearing portion 60. The bar 58 is configured to fitinto recesses or slots 62 in shelves 64 that are located on the insideof the actuator housing 26, at the rear portion thereof. This allows thetrigger piece 56 to rotate in a hinged fashion. The trigger 28, thus,extends from the front of the sprayer 20, and is operatively associatedwith the actuator housing 26.

[0029] The container 22, as shown in FIG. 4, can have a conventionalvalve stem 66 extending upward from the top 40 of the container. Thesprayer actuator 24 further comprises a conduit 68. The conduit 68 has afirst end and a second end. The conduit 68, in the embodiment shown,comprises several elements. These include: the nozzle 30 at the firstend (or front) of the conduit 68; a first upstanding conduit portion (or“segment” or “leg”) 70; a second angular conduit portion (or “segment”or “leg”) 72; a platform 74; and a cap portion 76 at the second end ofthe conduit 68. The second conduit portion forms an angle, α, with saidfirst segment 72 greater than 0°. In the embodiment shown in FIG. 4where the sprayer is configured to direct the spray in at an upwardangle, this angle α is greater than about 90° and less than about 180°In the embodiment shown in the drawings, the nozzle 30 is held in afixed location in the front of the actuator housing 26, and the capportion 76 of the conduit 68 is fit over the valve stem 66 of thecontainer 22. The first conduit portion 70 of the conduit 68 in thisembodiment, is more rigid than the second conduit portion 72 (the latteris preferably flexible). In this embodiment, the conduit 68 serves thedual purpose of channeling the contents of the container 22 to thenozzle 30 where they can be sprayed out of the container 22, and alsotransmitting a downward force on the valve stem 66 to release thecontents of the container 22.

[0030] The sprayer actuator 24 works in the following manner. When theuser pulls the trigger 28 inward toward the actuator housing 26, thiscauses the bearing portion 60 of the trigger piece 56 to press down onthe platform 74 on the conduit 68. This causes the first conduit portion70 of the conduit 68 to move downward and activates the valve stem 66 ofthe container. Since the nozzle 30 is in a fixed position, the flexiblenature of the second conduit portion 72 of the conduit 68 bends andpermits this downward movement to take place. The valve stem 66 permitsthe contents of the container 22 to be released. The contents of thecontainer flow through the conduit 68 and out the nozzle 30.

[0031] Numerous other embodiments having the features described hereinare possible, a few of which are described below. In other embodiments,for example, the narrowed waist region can be formed by all, or aportion of, the container 22, rather than being formed entirely as partof the actuator housing 26. In various embodiments, the actuator 24 canbe permanently affixed to the container 22, or the actuator 24 can beremovably affixed to the container 22. The actuator 24 can be removablyaffixed to the container 22 in any manner known in the art for removablyaffixing an article to a container, including but not limited to byscrew threads, bayonet fitments, and by a snap fit. In addition, ratherthan having the lower portion 42 of the actuator housing 26 overlap theoutside of the upper portion 38 of the container, the actuator 24 andcontainer 22 can be configured so that their outside surfaces are flushor form a substantially continuous surface.

[0032] In these or other embodiments, the conduit 68 need not compriseall of the elements described herein, and these elements can be providedas part of some other element of the sprayer actuator 24. In otherembodiments, the nozzle need not remain in a fixed position at the frontof the actuator housing 26. For example, it is possible for the nozzle30 to be mounted so that it moves upward and downward when the trigger28 is moved. In other embodiments, the conduit 68 need not comprise afirst and second conduit portion in which one of the conduit portions isflexible and one is more rigid. In other embodiments, for example, theentire conduit 68 can be flexible, or the entire conduit can be rigid.However, this may change the way that the sprayer actuator functions.

[0033] In other embodiments, the trigger piece 56 can comprise a portionof the actuator housing 26, or any other part of the actuator, ratherthan a separate component that is affixed to the actuator housing 26.Such a sprayer actuator need not comprise all of the features of thesprayer described herein. For example, FIG. 8 shows an example of aconventional sprayer 20 that has an actuating member, such as a pushbutton 80 at the top of the actuator housing 26. This push button 80 isformed as part of the actuator housing 26, and is joined to the actuatorhousing 26 in a manner (such as with a living hinge that flexes) thatpermits the push button to move slightly downward and back upward. Inthe variation of the sprayer 20 shown in FIG. 8, a trigger piece 56 isjoined to the front of the push button piece 80 to convert the sprayerinto a trigger sprayer. In this embodiment, the trigger 28 residesoutside of the front portion of the actuator housing 26. The triggerpiece 56 can be joined to the push button piece in any suitable manner,or it can be molded as an integral part of the push button piece 80and/or the actuator housing 26.

[0034] In still other embodiments, the trigger piece 56 and the conduit68 can be formed as a single integral component.

[0035]FIG. 7 shows one embodiment of a method for assembling of thecomponents of the sprayer actuator 24. As shown in FIG. 7, the sprayeractuator 24 is assembled as follows. The actuator housing 26 is providedin two portions comprising a side portion having a top that is at leastpartially open, a bottom that is at least partially open, and a frontwith an opening therein for the trigger, and a cap 48 for the actuatorhousing. The trigger piece 56 is inserted into said side portion of theactuator housing so that at least a portion of the trigger piece 56extends outward through the opening in the front of the side portion ofthe housing to form a trigger 28. The conduit 68 is inserted into theside portion of the actuator housing 26 so that it is in fluidcommunication with the container 22 and operatively associated with thetrigger 28. Finally, the cap forming the top 48 of the actuator housing26 is placed on top of the side portion of the housing to form thesprayer actuator.

[0036] The disclosure of all patents, patent applications (and anypatents which issue thereon, as well as any corresponding publishedforeign patent applications), and publications mentioned throughout thisdescription are hereby incorporated by reference herein. It is expresslynot admitted, however, that any of the documents incorporated byreference herein teach or disclose the present invention.

[0037] It should be understood that every maximum numerical limitationgiven throughout this specification will include every lower numericallimitation, as if such lower numerical limitations were expresslywritten herein. Every minimum numerical limitation given throughout thisspecification will include every higher numerical limitation, as if suchhigher numerical limitations were expressly written herein. Everynumerical range given throughout this specification will include everynarrower numerical range that falls within such broader numerical range,as if such narrower numerical ranges were all expressly written herein.

[0038] While particular embodiments of the subject invention have beendescribed, it will be obvious to those skilled in the art that variouschanges and modifications of the subject invention can be made withoutdeparting from the spirit and scope of the invention. In addition, whilethe present invention has been described in connection with certainspecific embodiments thereof, it is to be understood that this is by wayof illustration and not by way of limitation and the scope of theinvention is defined by the appended claims which should be construed asbroadly as the prior art will permit.

What is claimed is:
 1. An ergonomic sprayer actuator comprising ahousing having an upper portion, a lower portion for fitting on acontainer, and a narrowed waist portion between said upper portion andsaid lower portion.
 2. The ergonomic sprayer actuator of claim 1 whereinsaid actuator housing is configured so that a user can wrap at leasttheir thumb and forefinger around the narrowed waist portion, and whenviewed from above, at least a part of the upper portion extends outwardbeyond the portion of the user's thumb and forefinger that are incontact with the narrowed waist portion.
 3. The ergonomic sprayeractuator of claim 2 wherein said actuator housing has a front, a rear,and sides, and the part of the upper portion that extends outward beyondthe portion of the user's thumb and forefinger that are in contact withthe narrowed waist portion is at least on the sides and rear of thehousing.
 4. The ergonomic sprayer actuator of claim 3 wherein the partof the upper portion that extends outward beyond the portion of theuser's thumb and forefinger that are in contact with the narrowed waistportion also includes a portion at the front of the housing.
 5. Theergonomic sprayer actuator of claim 1 wherein said upper portion isconfigured so that it rests on a portion of a user's thumb andforefinger to at least partially support the weight of the sprayerduring use.
 6. The ergonomic sprayer actuator of claim 1 wherein saidupper portion has a front, a back, and an underside, and said upperportion is tilted so that the underside of said upper portion is higherin front than in the back.
 7. The ergonomic sprayer actuator of claim 1further comprising a nozzle at the front of said sprayer housing,wherein said nozzle is oriented so that liquid sprayed from said nozzlewill be directed at an angle of greater than 0° and less than 90°. 8.The ergonomic sprayer actuator of claim 1 further comprising a nozzle atthe front of said sprayer housing, wherein said nozzle is oriented sothat liquid sprayed from said nozzle will be directed at a downwardangle of less than 0° and greater than −90°.
 9. The ergonomic sprayeractuator of claim 1 further comprising a trigger operatively associatedwith said sprayer housing at the front of said sprayer.
 10. Theergonomic sprayer actuator of claim 9 wherein said trigger has a lengththat is sufficient to allow said trigger to be activated with twofingers.
 11. The ergonomic sprayer actuator of claim 10 wherein thelength of said trigger is greater than or equal to about 30 mm.
 12. Theergonomic sprayer actuator of claim 9 wherein the trigger has a width,and the width of said trigger is greater than or equal to about 15 mm.13. A sprayer comprising a non-pressurized container having a top andthe ergonomic sprayer actuator of claim 1 which is joined to the top ofthe container.
 14. A sprayer comprising a pressurized container having atop and the ergonomic sprayer actuator of claim 1 which is joined to thetop of the container.
 15. The sprayer of claim 14 wherein saidpressurized container comprises a propellant, and at least a portion ofsaid propellant comprises a compressed gas.
 16. The sprayer of claim 15wherein said compressed gas comprises one or more of the following:compressed air, nitrogen, one or more inert gases, and carbon dioxide.17. The sprayer of claim 15 which is configured to provide a spray inthe air in the form of a plurality of spray droplets, and at least someof the spray droplets have a diameter in a range of from about 0.01 μmto about 500 μm.
 18. The sprayer of claim 15 which is configured toprovide a spray in the air in the form of a plurality of spray droplets,and at least some of the spray droplets have a diameter in a range offrom about 5 μm to about 400 μm.
 19. The sprayer of claim 15 which isconfigured to provide a spray in the air in the form of a plurality ofspray droplets, and at least some of the spray droplets have a diameterin a range of from about 10 μm to about 200 μm.
 20. The sprayer of claim17 wherein at least some of the spray droplets have a mean diameter byvolume of between about 10-100 μm.
 21. The sprayer of claim 17 whereinat least some of the spray droplets have a mean diameter by volume ofbetween about 20-60 μm.
 22. A sprayer actuator for fitting on apressurized container having a valve stem, said sprayer actuator havinga front, said sprayer actuator comprising: a housing; a triggeroperatively associated with said housing at the front of said sprayeractuator; and a conduit having a first end and a second end, whereinsaid first end of said conduit is configured to be positioned over thevalve stem of a pressurized container, and the second end of saidconduit has a nozzle operatively associated therewith, wherein saidconduit is configured to provide fluid communication between apressurized container and said nozzle.
 23. The sprayer actuator of claim22 wherein said conduit comprises two rectilinear segments that form anangle there between.
 24. The sprayer actuator of claim 23 wherein saidtwo rectilinear segments comprise a first segment that comprises thefirst end of the conduit, wherein said first segment is disposed in asubstantially vertical orientation when the first end of the conduit ispositioned over the valve stem of a pressurized container, and a secondsegment that forms an angle with said first segment of greater thanabout 90° and less than about 180°.
 25. The sprayer actuator of claim 22wherein said conduit is curved.
 26. The sprayer actuator of claim 22wherein at least a portion of said conduit is flexible.
 27. The sprayeractuator of claim 24 wherein the second segment is flexible.
 28. Thesprayer actuator of claim 22 wherein said conduit further comprises abearing platform.
 29. The sprayer actuator of claim 22 wherein saidnozzle held in a fixed position when said trigger is activated.
 30. Thesprayer actuator of claim 22 wherein said nozzle is moveable when saidtrigger is activated.
 31. A sprayer comprising: a container having avalve stem; and an actuator on said container actuator comprising ahousing, said housing comprising an actuating member at least indirectlyin mechanical contact with said valve stem, having a trigger that isintegrally formed with at least a portion of said housing andoperatively associated with said sprayer housing at the front of saidsprayer actuator.
 32. A method of making a sprayer actuator comprising:providing a side portion for a housing of a sprayer actuator, said sideportion having a top that is at least partially open, a bottom that isat least partially open, and a front with an opening therein for atrigger; providing a trigger piece; providing a conduit; providing a capfor said sprayer housing; inserting said trigger piece into said sideportion of said housing so that at least a portion of said trigger pieceextends outward through the opening in the front of said side portion ofsaid housing to form a trigger; inserting said conduit into said sideportion of said housing so that it is operatively associated with saidtrigger; and placing said cap on top of said side portion of saidhousing to form said sprayer actuator.